U.S. patent number 10,013,661 [Application Number 14/271,806] was granted by the patent office on 2018-07-03 for method and system for monitoring plant operating capacity.
This patent grant is currently assigned to Nuvo Ventures, LLC. The grantee listed for this patent is Nuvo Ventures, LLC. Invention is credited to Jack Nuszen, Thomas Vo.
United States Patent |
10,013,661 |
Nuszen , et al. |
July 3, 2018 |
Method and system for monitoring plant operating capacity
Abstract
A monitoring system is disclosed for acquiring output activity,
utilization capacity and/or effluent data from an facility on a
facility-by-facility and/or an industry-by-industry basis. The
system is designed to generate a plant and/or industry output
activity database that is updated on a continuous, near continuous,
periodic and/or intermittent basis so that subscribers are apprised
of changes in plant or overall industry output. A clearing house is
also disclosed for distributing the acquired data to subscribers to
aid in analyzing, predicting trends, pricing, maintaining,
adjusting, minimizing, and/or maximizing individual plant or
overall industry output.
Inventors: |
Nuszen; Jack (Houston, TX),
Vo; Thomas (Bellaire, TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
Nuvo Ventures, LLC |
Houston |
TX |
US |
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Assignee: |
Nuvo Ventures, LLC (Houston,
TX)
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Family
ID: |
37460912 |
Appl.
No.: |
14/271,806 |
Filed: |
May 7, 2014 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20140324551 A1 |
Oct 30, 2014 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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11988975 |
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8738424 |
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PCT/US2006/032411 |
Aug 17, 2006 |
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60708990 |
Aug 17, 2005 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N
21/85 (20130101); G06Q 10/063 (20130101); G01N
21/3504 (20130101); G06Q 10/06313 (20130101); G06Q
50/26 (20130101) |
Current International
Class: |
G06Q
10/06 (20120101); G01N 21/3504 (20140101); G01N
21/85 (20060101); G06Q 50/26 (20120101) |
Field of
Search: |
;705/7.11 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Measurements of infrared and acoustic source distributions in jet
plumes (Apr. 2004). NASA. cited by examiner .
Pogorzala, D. (2004). Gas plume species identification by
regression analyses. RIT. cited by examiner .
Mesa-Martinez, F. (2007). Measuring performance, power, and
temperature from real processors. Univ. of CA. cited by examiner
.
Examples: Abstract Ideas, published by USPTO (no date). cited by
examiner.
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Primary Examiner: Ludwig; Peter L
Attorney, Agent or Firm: Ryan, Patent Agent; Thomas B.
Harter Secrest & Emery LLP
Parent Case Text
RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser.
No. 11/988,973 filed Mar. 16, 2009 as a national stage of
International Application No. PCT/US2006/032411 filed Aug. 17,
2006, which claims benefit of U.S. Provisional Application No.
60/708,990 filed Aug. 17, 2005.
Claims
The invention claimed is:
1. A method for monitoring, determining, and outputting at least
one of plant output activity and capacity utilization of at least
one power generating plant connected to a power grid comprising the
steps of: acquiring thermal images of at least one of one or more
stack effluent plumes produced by the at least one power generating
plant connected to the power grid using at least one thermal
imaging camera, storing the acquired thermal images of the at least
one of the one or more stack effluent plumes with at least one
processing unit, transmitting the stored thermal images of the at
least one of the one or more stack effluent plumes from the at
least one processing unit to a central processing center having at
least one processor, scanning the thermal images of the at least
one of the one or more stack effluent plumes with the at least one
processor to identify pixels within the thermal images containing
more than at least one of a background pixel intensity and a
threshold pixel intensity and thereby define active regions within
the transmitted thermal images, associating pixel intensities
within the active regions of the thermal images with the at least
one of plant output activity and capacity utilization supplied by
the at least one power generating plant to the power grid using the
at least one processor, and transmitting from the central
processing center to at least one of one or more user devices
information concerning the at least one of plant output activity
and capacity utilization supplied to the power grid based on the
associated pixel intensities within the active regions of the
thermal images.
2. The method of claim 1, further comprising the step of: prior to
the step of associating pixel intensities, correcting the pixel
data to compensate for existing environmental factors using a data
processing subsystem.
3. The method of claim 2, further comprising the steps of:
accumulating the information concerning the at least one of plant
output activity and capacity utilization supplied to the power grid
using an accumulation subsystem and determining trends using a
trend subsystem from the accumulated information concerning the at
least one of plant output activity and capacity utilization
supplied to the power grid.
4. The method of claim 3, further comprising the step of: producing
a report using a report subsystem evidencing the at least one of
plant output activity and capacity utilization over time.
5. The method of claim 1, wherein the at least one of the one or
more stack effluent plumes includes a plurality of stack effluent
plumes, the at least one power generating plant includes a
plurality of power generating plants, and the at least one thermal
imaging camera includes a plurality of thermal imaging cameras, and
wherein the step of acquiring thermal images includes acquiring
thermal images of the plurality of the stack effluent plumes
produced by the plurality of the power generating plants connected
to the power grid using the plurality of thermal imaging
cameras.
6. The method of claim 5, wherein the step of transmitting from the
central processing center includes transmitting the information
concerning the at least one of plant output activity and capacity
utilization supplied to the power grid by each of the plurality of
the power generating plants based on the associated pixel
intensities within the active regions of the thermal images.
7. The method of claim 1, wherein the step of associating pixel
intensities includes comparing the pixel intensities within the
active regions of the thermal images against a baseline of
previously acquired data, and further comprising a step of
predicting disruptions in the power grid based on the
comparison.
8. The method of claim 7, wherein the previously acquired data
includes data from the stored thermal images collected over
time.
9. The method of claim 7, wherein the step of transmitting from the
central processing center includes transmitting information
concerning the predicted disruptions from the central processing
center to the at least one of the one or more user devices.
10. The method of claim 1, wherein the step of transmitting from
the central processing center includes transmitting information
concerning the at least one of plant output activity and capacity
utilization of the at least one power generating plant to a
clearinghouse where the information is accessible to a plurality of
users in a form that reveals trends.
11. The method of claim 1, further comprising a step of connecting
the at least one thermal imaging camera to the power grid using a
power conditioning unit.
12. The method of claim 2, wherein the step of correcting includes
correcting the pixel data to compensate for weather conditions
using a data processing subsystem.
13. The method of claim 12, wherein the step of correcting includes
applying a correction factor to pixels data in the active
regions.
14. A method for monitoring, determining, and outputting at least
one of plant output activity and capacity utilization of at least
one power generating plant connected to a power grid comprising the
steps of: acquiring thermal images of at least one of one or more
stack effluent plumes produced by the at least one power generating
plant connected to the power grid using at least one thermal
imaging camera, storing the acquired thermal images of the at least
one of the one or more stack effluent plumes with at least one
processing unit, transmitting the stored thermal images of the at
least one of the one or more stack effluent plumes from the at
least one processing unit to a processor, scanning the thermal
images of the at least one of the one or more stack effluent plumes
with the processor to identify pixels within the thermal images
containing more than at least one of a background pixel intensity
and a threshold pixel intensity and thereby define active regions
within the transmitted thermal images, associating pixel
intensities within the active regions of the thermal images with
the at least one of plant output activity and capacity utilization
supplied by the at least one power generating plant to the power
grid using the processor, and transmitting from the processor to at
least one of one or more user devices information concerning the at
least one of plant output activity and capacity utilization
supplied to the power grid based on the associated pixel
intensities within the active regions of the thermal images.
Description
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a system and method for monitoring
industrial plant activity and to a system and method for using the
monitoring data to stabilize plant and industrial productivity, to
maximize plant and overall industrial productivity, to track and
evaluate plant and industrial productivity, and/or to develop
global data dissemination methodologies and/or to develop global
industrial responses to natural or man-made industry
disruptions.
More particularly, the present invention relates to a system and
method for monitoring industrial plant activity, where the method
includes imaging plant stacks and/or effluent plumes and relating
data derived from the images to an index of plant activity. This
invention also relates to a system and method for using the
monitoring data to stabilize plant and industrial productivity, to
maximize plant and overall industrial productivity, to track and
evaluate plant and industrial productivity, and/or to develop
global data dissemination methodologies and/or to develop global
industrial responses to natural or man-made industry disruptions,
where the method includes packaging the plant activity data so that
industrial participants and governmental regulatory agencies can
change plant and/or industrial output and productivity to adjust,
stabilize and/or maximize output of desired industries.
Description of the Related Art
Camera and other detection system designed to image plant effluents
and thermal emissions have been used for many years to analyze
thermal output and effluent compositions for environmental,
operational and emission control. Many of these systems are
designed to determine effluent plume composition and effluent plume
disbursement. However, such systems have not been used to monitor
plant output, down time, cycle time, disruptions, etc. in a real
time or near real time so that industry and government can better
manage overall output and maintain adequate levels of goods and
services and so governments, brokers and analysts can be forecast
demand and supply economics.
Thus, there is a need in the art for a system and method for
monitoring stack and/or effluent plumes and relating data derived
therefrom to a measure of plant productivity and industry
productivity and packaging the plant and industry productivity data
into a format for instantaneous, periodic or intermittent
distribution to broker, analyst, industrial and governmental
organizations.
SUMMARY OF THE INVENTION
Systems
The present invention provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility and/or a unit
and/or units thereof to obtain, produce, store and transmit image
data. The system also includes (2) an analysis subsystem for
converting the image data into plant output activity data or
capacity utilization data.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image data. The
system also includes (2) a data processing subsystem capable of
correcting the image data for existing environmental factors. The
system also includes (3) an analysis subsystem for converting the
corrected image data into plant output activity or capacity
utilization data.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image data. The
system also includes (2) an analysis subsystem for converting the
image data into plant output activity or capacity utilization data.
The system also includes (3) an accumulation subsystem adapted to
accumulate the plant output activity or capacity utilization
data.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image data. The
system also includes (2) an analysis subsystem for converting the
image data into plant output activity or capacity utilization data.
The system also includes (3) an accumulation subsystem adapted to
accumulate the plant output activity or capacity utilization. The
system also includes (4) a trend subsystem adapted to determine
trends in plant activity or capacity utilization data.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image output
activity or capacity utilization data. The system also includes (2)
a data processing subsystem capable of correcting the image output
data for existing environmental factors. The system also includes
(3) an analysis subsystem for converting the corrected image data
into plant output activity or capacity utilization data. The system
also includes (4) an accumulation subsystem adapted to accumulate
the plant output activity or capacity utilization data. The system
also includes (5) a trend subsystem adapted to determine trends in
plant activity or capacity utilization data.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image output
activity or capacity utilization data. The system also includes (2)
an analysis subsystem for converting the image data into plant
output activity or capacity utilization data. The system also
includes (3) an accumulation subsystem adapted to accumulate the
plant output activity or capacity utilization data. The system also
includes (4) a trend subsystem adapted to determine trends in plant
output activity or capacity utilization data. The system also
includes (5) a report subsystem designed to report plant and/or
industry output capacity, capacity utilization, and overall plant
or industrial trends to end users.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image output
activity or capacity utilization data. The system also includes (2)
a data processing subsystem capable of correcting the image output
activity or capacity utilization data for existing environmental
factors. The system also includes (3) an analysis subsystem for
converting the corrected image output data into plant output
capacity data. The system also includes (4) an accumulation
subsystem adapted to accumulate the plant output capacity data. The
system also includes (5) a trend subsystem adapted to determine
trends in plant output data and a report subsystem designed to
produce an industry survey of industrial capacity, maximum output,
and/or output trends.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image output data.
The system also includes (2) an analysis subsystem for converting
the image data into plant output capacity data. The system also
includes (3) an accumulation subsystem adapted to accumulate the
plant output capacity data, a trend subsystem adapted to determine
trends in plant output data. The system also includes (4) a report
subsystem designed to produce an industry survey of industrial
capacity data, maximum output, and output trends. The system also
includes (5) an adjustment subsystem designed to adjust individual
facility output to adjust and/or maximize overall all industrial
output.
The present invention also provides a system for monitoring and
determining plant output activity or capacity utilization including
(1) an imaging subsystem capable of imaging stacks of and/or
effluent plumes generated by an industrial facility or units
thereof to obtain, produce, store and transmit image output data.
The system also includes (2) a data processing subsystem capable of
correcting the image output data for existing environmental
factors. The system also includes (3) an analysis subsystem for
converting the corrected image data into plant output capacity
data. The system also includes (4) an accumulation subsystem
adapted to accumulate the plant output capacity data. The system
also includes (5) a trend subsystem adapted to determine trends in
plant output data. The system also includes (6) a report subsystem
designed to produce an industry survey of industrial capacity,
maximum output, and/or output trends. The system also includes (7)
an adjustment subsystem designed to adjust individual facility
output to adjust and/or maximize overall all industrial output.
In all of the above systems, the imaging subsystem can be adapted
to image stack plumes to determine temperature and compositional
profiles of the plume intermittently, periodically,
semi-continuously, or continuously. Thermal and compositional data
can either be obtained using a single camera system with different
filters that select light characteristic of a given atomic and/or
molecular species or using composition specific cameras or sensors
in parallel or series. In the case of a single camera system, the
imaging system can include a series of filter that are
intermittently, periodically or continuously interchanged so that
each image type is acquired on an intermittent, periodic or
continuous basis. It should be recognized that each data collection
for each different filter can be continuously collected or
collected over a period of time and if over a period of time, each
acquisition period can be the same of different. It should also be
recognized that operating in a continuous switching mode does not
mean that the collected data for each filter is temporally
continuous (clearly when one image is being collected, the other
images are not), but that each image type is being collected in a
continuous rotation during a given monitoring period. Such a
continuous switching mode of operation can be contrasted with a
mode where one image type is collected continuously, except for
intermittent or periodic collections of the other image types.
Thus, the data from the first image type will be temporally much
more complete, save for the time required to switch from its filter
to a second filter, to collect a data set or image from the second
filter and switch back, while the data from the second image type
will be intermittent or periodic, with large temporal gaps between
the collected data sets or images. Clearly, the data from the first
image type will be periodic if the data from the second image type
is periodic, but the first data set will have only small temporal
data gaps, while the second data set will have large temporal data
gaps.
For imaging subsystems having multiple detectors, cameras or
sensors, the subsystem can either utilized multiple images (e.g.,
each camera or sensor can collect its own light) or the subsystem
can include one or more beam splitters capable of splitting a
single image into a plurality of images. Thus, a single image can
be used by all detectors or the number of light collections,
images, can be less than or equal to the number of detectors in the
imaging subsystem. It should be recognized that the detectors,
cameras or sensors convert incident light in an electronic signal
that is capable of being analyzed. Generally, the initial
electronic signal is an analog signal that is converted into a
digital system prior to analyzing the data.
Methods
The present invention provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks of and/or
effluent plumes generated by an industrial facility and/or a unit
and/or units thereof. Once the image data has been acquired, the
method also includes the step (2) analyzing or converting the image
data into plant output activity or capacity utilization data.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks of and/or
effluent plumes generated by an industrial facility and/or a unit
and/or units thereof. Once the image data has been acquired, the
method also includes the step (2) processing the image data to
correct the image data for existing environmental factors. After
image correction, the method also includes the step (3) analyzing
or converting the corrected image data into plant output activity
or capacity utilization data.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks and/or
effluent plumes generated by an industrial facility or units
thereof. Once the image data has been acquired, the method also
includes the step (2) analyzing or converting the image data into
plant output activity or capacity utilization data. After data
conversion, the method also includes the step of (3) accumulating
the plant output activity or capacity utilization data. After data
accumulation, the method also includes the step of (4) generating
data trends derived from the plant output activity or capacity
utilization data.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks and/or
effluent plumes generated by an industrial facility or units
thereof. Once the image data has been acquired, the method also
includes the step (2) correcting the image data for existing
environmental factors. After image data correction, the method also
includes the step (3) converting the corrected image data into
plant output activity or capacity utilization data. After data
conversion the method also includes the step (4) accumulating the
plant output activity or capacity utilization data over time. After
data accumulation, the method also includes the step (5) generating
trends in plant output activity or capacity utilization data.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks and/or
effluent plumes generated by an industrial facility or units
thereof. Once the image data has been acquired, the method also
includes the step (2) converting the image data into plant output
activity or capacity utilization data. After data conversion, the
method also includes the step (3) accumulating the plant output
activity and capacity utilization data. After data accumulation,
the method also includes the step (4) generating trends in plant
output activity or capacity utilization data and (5) generating
reports derived from the plant output activity or capacity
utilization and generated trends for end users.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks and/or
effluent plumes generated by an industrial facility or units
thereof. Once the image data has been acquired, the method also
includes the step (2) correcting the image data for existing
environmental factors. After data correction, the method also
includes the step (3) converting the corrected image data into
plant output activity or capacity utilization data. After data
conversion, the method also includes the step (4) accumulating the
plant output activity or capacity utilization data over time. After
data accumulation, the method also includes the step (5) generating
trends in plant output activity and capacity utilization data and
(6) generating reports derived from the plant output activity or
capacity utilization and generated trends for end users.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks and/or
effluent plumes generated by an industrial facility or units
thereof. Once the image data has been acquired, the method also
includes the step (2) converting the image data into plant output
activity or capacity utilization data. After data conversion, the
method also includes the step (3) accumulating the plant output
activity or capacity utilization data over time. After data
accumulation, the method also includes the step (4) generating
trends in plant output activity or capacity utilization data and
(5) generating reports derived from the plant output activity or
capacity utilization and generated trends for end users. The method
can also include the step of (6) adjusting individual facility
output to adjust and/or maximize overall all industrial output or
any part thereof.
The present invention also provides a method for monitoring and
determining plant output activity or capacity utilization including
the step of (1) imaging or acquiring image data of stacks and/or
effluent plumes generated by an industrial facility or units
thereof. Once the image data has been acquired, the method also
includes the step (2) correcting the image output data for existing
environmental factors. After data correction, the method also
includes the step (3) converting the corrected image data into
plant output activity or capacity utilization data. After data
conversion, the method also includes the step (4) accumulating the
plant output activity or capacity utilization data over time. After
data accumulation, the method also includes the step (5) generating
trends in the plant output activity or capacity utilization data
and (6) generating reports derived from the plant output activity
or capacity utilization and generated trends for end users The
method can also include the step of (7) adjusting individual
facility output to adjust and/or maximize overall all industrial
output or any part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the
following detailed description together with the appended
illustrative drawings in which like elements are numbered the
same.
FIG. 1A depicts a block diagram of an embodiment of a plant
monitoring system of this invention.
FIG. 1B depicts a block diagram of another preferred embodiment of
a plant monitoring system of this invention.
FIG. 1C depicts a side view of a system of either FIG. 1A or FIG.
1B.
FIGS. 1D-E depict two views of another embodiment of mount assembly
of this invention.
FIG. 2A depicts a block diagram of another embodiment of a plant
monitoring system of this invention.
FIG. 2B depicts a block diagram of another preferred embodiment of
a plant monitoring system of this invention.
FIGS. 3A&B depict a block diagram of another embodiment of an
imaging apparatus of this invention.
FIG. 3C depicts an imaging apparatus of FIGS. 3A&B mounted on a
pole.
FIG. 3D depicts a cross-sectional view of the mount of FIG. 3C.
FIG. 4 depicts an embodiment of an imaging apparatus with multiple
filters of this invention.
FIG. 5 depicts an embodiment of a multiple camera imaging apparatus
of this invention.
FIG. 6 depicts an embodiment of an imaging apparatus with a beam
splitter of this invention.
FIG. 7 depicts another embodiment of an imaging apparatus with a
compound beam splitter of this invention.
FIG. 8 depict a block diagram of an embodiment of a multi-site
system of this invention.
FIG. 9 depicts a conceptual flow chart of a process of
initializing, calibrating and establishing a one hundred percent
output capacity value for a given plant or plant unit.
FIG. 10 depicts a conceptual flow chart of a process a plant output
monitoring, transmitting and collecting process of this
invention.
FIG. 11 depicts a conceptual flow chart of another process a plant
output monitoring, transmitting and collecting process of this
invention.
FIGS. 12A-C depict three conceptual flow charts of three
subprocesses for processing an acquired image to obtain pixel
density data.
FIG. 13 depicts a plot of data collected form a three stack
facility showing the thermal data image of the three stacks in the
facility from an IR camera located approximately 1 km from the
facility.
FIG. 14 depicts a plot of daily output activity for the facility in
FIG. 13.
DETAILED DESCRIPTION OF THE INVENTION
The inventors have found that a system and method can be
constructed that uses IR cameras to determine intermittent,
periodic, near instantaneous, and/or instantaneous plant capacities
of plants of a desired industry. The system and method are designed
to utilize data obtained from an IR camera imaging exhaust plumes
from exhaust outputs such as stacks outputs. These images are
designed to be obtained on an intermittent, periodic, near
instantaneous, and/or instantaneous basis and plume size data are
then related to plant activity. The activity data is then used to
project overall unit, plant, regional, national, or industrial
output to allow for intermittent, periodic, near instantaneous,
and/or instantaneous adjustments to overall industrial output so
that industrial output across the spectrum can be evened out and/or
maximized. The system and method is designed to accumulate data for
a sufficient time to determine a base line for determining a
particular plant's activity profile so that plume image data can be
directly related to plant output within a given confidence level.
The system is also designed to provide end users to access unit,
plant, regional, industry wide, etc. data on output activity,
capacity utilization, emissions, effluent volumes, etc. for
forecasting purposes, supply and demand analyses and other
industrial indicators. All of the data analyses performed for end
users is subject to pricing for revenue generation purposes.
The present invention relates broadly to a system for monitoring
and determining plant output capacity including an imaging
subsystem capable of imaging effluent plumes generated by an
industrial facility or units thereof and producing image output
data and an analysis subsystem for converting the image data into
plant output capacity data.
The present invention provides. a method for monitoring and
determining plant output capacity including an imaging subsystem
capable of imaging effluent plumes generated by an industrial
facility or units thereof and producing image output data and an
analysis subsystem for converting the image data into plant output
capacity data.
In order to monitor plant output activity or capacity utilization,
a detection device is adapted to observe and/or monitor one
property or a plurality of properties of the plant that can be
related to plant output activity or capacity utilization. One such
property of a plant that can be monitored at a distance is heat
associate with thermal stacks and/or stack exhaust effluent
streams. For plants that exhaust gases, the detection device is
adapted to image an exhaust stack and/or a plume associated with
the exhaust stack. The area/volume of the exhaust plume or the
stack as imaged by an imaging apparatus such as an IR camera is
captured at a given moment in time, continuously captured, or
accumulated for a period of time at regular intervals to establish
a plant base line or a mean average value of plant output activity
or capacity utilization. In the case continuous imaging
apparatuses, continuous images are taken over a short period of
time at regular intervals, where the images taken over the short
periods of time are accumulated to form a single composite image.
If the base line or mean average value does not vary by more than a
set amount, then the mean average value is set to a 100 percent
value. As monitoring continues, deviations from the 100 percent
value will either indicate a reduction in plant output or an
increase in plant output. If the increase is maintained for a
non-temporary time, a new 100 percent value is established. If the
100 percent value originally collected is consistent over time,
then changes in the measured value will represent disruptions in
the plant output, generally decreases in plant output. If the
system is designed to measure non-nuclear power generation
facilities, then the data can be used to predict disruptions in the
grid and to adjust individual plant outputs to maintain a given
level of overall output, to maximize overall output or to adjust
overall output to some desired level. In the case of a nuclear
power generation facility, the monitor is designed to monitor
output water used in the secondary coolant loop in a nuclear power
facility or in the effluent water to monitor water temperature,
output and to look for detectable radio-pollutants.
The system is designed to monitor plant activity from a distance.
Generally, the distance can be between about 25 m (meters) to about
10 km (kilometers) depending on the type of imaging device being
utilized. Preferably, the distance is between about 100 m and about
5 km and particularly between about 100 m and about 1 km.
When the system first starts monitoring a given plant, it will not
know whether the plant is operating at full capacity. Thus, the
system is designed to accumulate data over a sufficient period to
time to ascertain whether a given plant output remains
substantially constant over the period of time, where the term
substantially constant means that the plant output does not
deviated more than about 10% over the period of time. In another
preferred embodiment, the plant output does not deviate more than
about 5% over the period of time. The in yet another preferred
embodiment, the plant output does not deviate more than about 1%
over the period of time. The period of time is generally a month,
preferably, two weeks and, particularly, one week. Once the output
of a plant has been determined, its 100 percent is entered into a
database.
Generally, plant output data is acquired periodically over the
period of time. The period for data acquisition is generally
between the acquisition rate of the imaging device, if not
continuous, and about 1 day. In a preferred embodiment, the
acquisition rate is between about 1 second and 1 hour. In yet
another embodiment, the acquisition rate is between about 1 minute
and about 1 hour. In yet another embodiment, the acquisition rate
is between about 5 minutes and about 45 minutes. In yet another
embodiment, the acquisition rate is between about 10 minutes and
about 30 minutes. In yet another embodiment, the acquisition rate
is between about 10 minutes and about 20 minutes. In yet another
embodiment, the acquisition rate is between about 15. This same
data acquisition rate is also used for continued monitoring.
Data is then collected for plants within a given industry to form a
database for that industry. Once the database is constructed,
monitoring allows the system to detect on an instantaneous, a near
instantaneous, periodic or intermittent basis alterations in the
output of each plant in the given industry. Upon the detection of a
disruption in the overall output of a given industry, information
associated with the disruption can be sent to local, state and
federal oversight agencies and the data can be distributed to other
plants within the given industry of the change in overall capacity
so that the other plants can adjust their output to compensate for
the disruption.
The present invention also relates to a business method for
detecting, tracking, compiling and distributing information on an
industry-by-industry basis to permit any given industry to adjust
specific plant activities so that an overall industrial output can
be maintained, adjusted and/or maximized. The information will, of
course, be associated with a fee associated with the monitoring,
tracking, compiling and distributing of the acquired data. Thus,
the present invention also relates to an industry output
clearinghouse, where members of a given industry will subscribe to
the clearinghouse and will be given data on a continuous,
semi-continuous, periodic and/or intermittent basis concerning
overall industrial output, output trends, specific plant output
data and/or alters signifying changes in the output of one, some or
all plants within the given industry. The clearinghouse data will
better allow industrial players to determine overall industrial
needs and treads and to better adjust individual plant outputs to
maintain, adjust, minimize and/or maximize industrial overall
output or activity. The clearinghouse data will also be able to
identify quickly changes in a specific plant output such as a plant
undergoing a de-bottlenecking operation or other modifications to
increase plant output. The clearinghouse will give industry players
quick and reliable data for maximizing profits, output and/or
expenditures to increase specific plant capacity. The clearinghouse
data will also show longer term trends in given industries and be
able to identify early regional output disruptions or regions where
additional capacity is needed to keep up with demand. The data will
also allow industrial players to better positions its output
capacity to maximize return on investment and to maximize profits
and minimize losses.
Suitable IR cameras include, without limitation, IR cameras
manufactured by Honeywell Corporation, Thermoteknix Systems Ltd of
Cambridge, England (Visir camera, Miric 500, Miric 11, etc.),
Infrared Solutions Inc. of Minneapolis, Minn., USA (IR-160), FLIR
Systems, Inc. of North Billerica, Mass., USA (A series infrared
camera, Thermovision 2000, Thermovision Ranger II and Sentry,
etc.), Diversified Optical Products, Inc. of Salem, N.H., USA
(Lanscout 50, 75, 125, Lanscout 60/180, Range Pro 50/250, etc.),
Leake Company of Dallas, Tex., USA (Thermal Sentry), Spirit
Solutions, Inc., and other similar IR camera systems. Preferably,
the cameras employ an infrared array detection system. Infrared
array detections systems are available from Raytheon Company of
Waltham, Mass., USA, DRS Technologies, Inc., Santa Barbara Research
Center, University of California at Santa Barbara, Cal Sensors,
Inc. of Santa Rosa, Calif., USA, HGH Systemes Infrarouges ZAC,
IGNY, FRANCE, ULIS of Veurey Voroize France, and other manufactures
that make IR array detectors. It should be recognized that there
are different array technologies. Several of these technologies
include Amorphous Silicon (ASi) Focal Plane Array (FPA) and Barium
Strontium Titanate (BST) FPA. Currently, the inventors have had
their best results with the BST FPA array.
Suitable compositional detectors include, without limitation, any
detector that is capable of detecting light characteristic of a
given atomic and/or molecular system. Generally, the detectors are
optimized for a particular wavelength of light and filters are used
to eliminate light not in the detectors spectral sensitive regions.
However, a detector can be used with broad and uniform response
characteristics, with light restriction occurring by judicious
selection of filters designed to pass light of a desired wavelength
range, where the range is characteristic of a certain chemical
compound of class of chemical compounds that have a similar optical
emission spectrum within the range. One of ordinary skill in the
art are aware of such filters that are selectively sensitive to
hydrocarbon optical (Visible, IR, near IR, microwave, etc.)
signatures, nitrogen oxide optical signatures, sulfur oxide optical
signatures, water (liquid and/or vapor) optical signatures, carbon
oxide optical signatures, etc.
Suitable digital processing units include, without limitation,
computers having a processing chip and memory chips manufactured by
Intel, Motorola, AMD, Cyrix, Erickson, or mixtures or combinations
thereof. The digital processing units include peripheral such as,
without limitation, internal and/or external mass storage devices
such as disk drives, solid state disk drives, tape drives, memory
stick, memory cards, etc., communication hardware and software,
printers, scanners, etc.
Single Imaging Subsystem--Plume Imaging
Referring now to FIG. 1A, a preferred embodiment of an IR imaging
system of this invention, generally 100, is shown to include an
imaging assembly 102. In one embodiment, the imaging assembly 102
includes a pole 104, a mount assembly 106 disposed on a top 108 of
the pole 104 and an imaging unit 110 mounted on the mount assembly
106. One of ordinary skill in the art should recognize that the
imaging assembly 102 can extend from the ground, from the top of a
building, or from any other object that allows the imaging unit 110
to have a clear line of sight image of the target plant or plant
stacks that are used to obtain information on plant or plant unit
activity and to obtain other information including a monitor of the
type of materials being exhausted from the stacks. Of course, if
the effluent is a liquid, such as waste water, the imaging unit 110
would be situated to image the effluent. If effluent compositional
data are being collected as well as plant or plant unit output
capacity data, then the imaging unit may include more than one
imaging camera, each having a different filter or the imaging unit
is capable of collecting data over a large frequency range and the
resulting image data can be mathematically filtered.
The imaging assembly 102 is located a specific distance from a
plant 112, which is shown to have four exhaust stacks 114a-d, which
are monitored to determine the plant's output at any given time.
The imaging unit 110 is positioned so that the imaging unit 110 can
acquire an image 116 which includes four active regions 118a-d
associated with the four stacks 114a-d, respectively. Of course, if
it is determined that the four stacks produce equal plant capacity
data (each stack accounts for 1/4 of the plant output), then only
one active region need be analyzed.
The imaging system 100 also includes a remote processing center 120
in data communication with the imaging unit 110 via a data flow
pathway 122. The data communication can be wireless or wired. If
wireless, the data communication can line of sight or more
preferably the signal can be transmitted via cell phone networks or
satellite networks onto a distributed network such as the internet
or a secured distributor network.
Multiple Imaging Subsystem--Plume Imaging
Referring now to FIG. 1B, another preferred embodiment of an IR
imaging system of this invention, generally 150, is shown to
include four imaging assemblies 152a-d. In one embodiment, each of
the imaging assemblies 152a-d includes a pole 154a-d, a mount
assembly 156a-d disposed on a top 158a-d of the pole 154a-d and an
imaging unit 160a-d mounted on the mount assemblies 156a-d,
respectively. One of ordinary skill in the art should recognize
that the imaging assemblies 152a-d can extend from the ground, from
the top of a building, or from any other object that allow the
imaging units 160a-d to have a clear line of sight image of the
plant stacks that are used to obtain information on plant or plant
unit activity and to obtain other information including a monitor
of the type of materials being exhausted from the stacks. Of
course, if the effluent is a liquid, such as waste water, the
imaging units 160a-d would be situated to image the effluent. If
effluent compositional data are being collected as well as plant or
plant unit output capacity data, then the imaging units may include
more than one imaging camera, each having a different filter or the
imaging units are capable of collecting data over a large frequency
range and the resulting image data can be mathematically
filtered.
Each of the imaging assemblies 152a-d is located a specific
distance from a plant 162, which is shown to have four exhaust
stacks 164a-d, so that the assembly 152a is focused on the stack
164a, the assembly 152b is focused on the stack 164b, the assembly
152c is focused on the stack 164c, and the assembly 152d is focused
on the stack 164d. This configuration allows each stack to be
separating monitored which can increase the amount and type of
information extractable from the images. This configuration is
especially useful when the output stacks of interest are incapable
of being efficiently imaged from a single location or the distance
from the imaging unit prevents ready complete imaging as in FIG.
1A.
Each of the imaging units 160a-d is positioned so that each of the
imaging unit 160a-d can acquire an image 166a-d which includes a
stack active region 168a-d, respectively.
The imaging system 150 also includes a remote processing center 170
in data communication with the imaging units 160a-d, via data flow
pathways 172a-d. The data communication can be wireless or wired.
If wireless, the data communication can line of sight or more
preferably the signal can be transmitted via cell phone networks or
satellite networks onto a distributed network such as the internet
or a secured distributor network.
Imaging Subsystem Views--Plume Imaging
Referring now to FIG. 1C, a side view of the plant configuration of
FIGS. 1A&B is shown. The view show an imaging assembly 102 or
152 and the distance D to the stacks and the resulting vertical
image positioning V resulting from a view angle A. The apparatus
100 also includes a processing unit 170 in electrical communication
via a communication pathway 172 (which can be a cable supporting
wired based data communication or a wireless format supporting
wireless data communication) with the imaging unit (camera) 110.
The processing unit 170 generally includes computer hardware and
software and communication hardware and software need to capture,
store, analyze and/or transmit the image data captured by the
imaging unit 110 to the central processing center 120.
Referring now to FIGS. 1D-E, a preferred embodiment of the mount
assembly 106 or 156a-d is shown to include a portion 124 of the
pole 104 or 154a-d. Mounted on the top 108 or 158a-d of the pole
104 or 154a-d, respectively, is mount 126 supporting a shaft 128,
which is attached to the imaging unit 110 or 160a-d via a ball
joint 130. The ball joint 130 allows the imaging unit 110 or 160a-d
to be adjusted up and down 132 as shown in FIG. 1D or side to side
134 as shown in FIG. 1E. Of course, the imaging unit 110 or 160a-d
can be mounted on the mount 126 by any assembly that permits the
imaging unit 110 or 160a-d to be adjusted in two orthogonal
directions, e.g., up and down and side to side. Moreover, the
assembly can be motorized so that the imaging unit can be adjusted
remotely. Such remote adjust capability can be used to allow the
imaging unit to image specific areas of interest. Furthermore, the
imaging unit aperture can be motorized under remote control so that
the imaging unit can be controlled to image a specific area and to
limit the image being captures. The imaging unit can also be
equipped with magnifying lens to further refine the imaged
area.
Single Imaging Subsystem--Stack and Plume Imaging
Referring now to FIG. 2A, another embodiment of an IR imaging
system of this invention, generally 200, is shown to include an
imaging assembly 202. The imaging assembly 202 includes a pole 204,
a mount assembly 206 disposed near a top 208 of the pole 204 and an
imaging unit 210 mounted on the mount assembly 206. One of ordinary
skill in the art should recognize that the imaging assembly 202 can
extend from the ground, from the top of a building, or from any
other object that allows the imaging unit 210 to have a clear line
of sight image of the target plant or plant stacks that are to be
used to obtain information on plant or plant unit activity and to
obtain other information including monitoring the type of materials
being exhausted from the stacks. Of course, if the effluent is a
liquid, such as waste water, the imaging unit 210 would be situated
to image pipe near its exit and the effluent issued therefrom. If
effluent compositional data are being collected as well as plant or
plant unit output activity and capacity utilization data, then the
imaging unit may include more than one imaging camera and/or
detector, each having a different filter or the imaging unit is
capable of collecting data over a large frequency range and the
resulting image data can be physically or mathematically filtered
pre- or post-data acquisition.
The imaging assembly 202 is located a specific distance from a
plant 212, which is shown to include four exhaust stacks 214a-d,
which are monitored to determine the plant's output activity or
capacity utilization at any given time or time interval. The
imaging unit 210 is positioned so that the imaging unit 210 can
acquire an image 216 which includes four the four stacks 214a-d and
four active regions 218a-d associated with the four stacks 214a-d,
respectively. Of course, if it is determined that the four stack
produce equal plant output activity or capacity utilization data
(each stack accounting for 1/4 of the plant output), then only one
stack and/or active region need be analyzed.
The imaging system 200 also includes a remote data storage,
processing and analyzing center 220 in data communication with the
imaging unit 210 via a data flow pathway 222. The data
communication can be wireless or wired. If wireless, the data
communication can line of sight or more preferably the signal can
be transmitted via cell phone networks or satellite networks onto a
distributed network such as the internet or a secured distributor
network.
The imaging unit 210 also includes a power conditioning unit 224
connected to a power grid (not shown) and to the imaging unit 210
via a power supply line 226. The imaging unit 210 also includes a
lightning rod 228 connected to a ground 230 by a ground wire 232.
The assembly 202 also includes a protective top shield 234.
Multiple Imaging Subsystem--Stack and Plume Imaging
Referring now to FIG. 2B, another embodiment of an IR imaging
system of this invention, generally 250, is shown to include four
imaging assemblies 252a-d. In one embodiment, each of the imaging
assemblies 252a-d includes a pole 254a-d, a mount assembly 256a-d
disposed on a top 258a-d of the pole 254a-d and an imaging unit
260a-d mounted on the mount assemblies 256a-d, respectively. One of
ordinary skill in the art should recognize that the imaging
assemblies 252a-d can extend from the ground, from the top of a
building, or from any other object that allow the imaging units
260a-d to have a clear line of sight image of the plant stacks that
are used to obtain information on plant or plant unit activity and
to obtain other information including a monitor of the type of
materials being exhausted from the stacks. Of course, if the
effluent is a liquid, such as waste water, the imaging units 260a-d
would be situated to image the effluent. If effluent compositional
data are being collected as well as plant or plant unit output
capacity data, then the imaging units may include more than one
imaging camera, each having a different filter or the imaging units
are capable of collecting data over a large frequency range and the
resulting image data can be mathematically filtered.
Each of the imaging assemblies 252a-d is located a specific
distance from a plant 262, which is shown to have four exhaust
stacks 264a-d, so that the assembly 252a is focused on the stack
264a, the assembly 252b is focused on the stack 264b, the assembly
252c is focused on the stack 264c, and the assembly 252d is focused
on the stack 264d. This configuration allows each stack to be
separating monitored which can increase the amount and type of
information extractable from the images. This configuration is
especially useful when the output stacks of interest are incapable
of being efficiently imaged from a single location or the distance
from the imaging unit prevents ready complete imaging as in FIG.
2A.
Each of the imaging units 260a-d is positioned so that each of the
imaging unit 260a-d can acquire an image 266a-d which includes the
stacks 264a-d and stack active regions 268a-d, respectively.
The imaging system 250 also includes a remote processing center 270
in data communication with the imaging units 260a-d, via data flow
pathways 272a-d. The data communication can be wireless or wired.
If wireless, the data communication can line of sight or more
preferably the signal can be transmitted via cell phone networks or
satellite networks onto a distributed network such as the internet
or a secured distributor network.
The imaging units 260a-d also include power conditioning units
274a-d connected to a power grid (not shown) and to the imaging
units 260a-d via power supply lines 276a-d. The imaging units
260a-d also include lightning rods 278a-d connected to grounds
280a-d by ground wires 282a-d. The assemblies 252a-d also includes
protective top shields 284a-d.
Alternate Single Imaging Subsystem
Referring now to FIGS. 3A&B, another embodiment of an imaging
apparatus of this invention, generally 300, is shown to include a
housing 302 having a front half 304 including a handle 306 attached
to a front surface 308 thereof and a back half 310 including a back
surface 312 adapted to permit the housing 302 to be mounted on a
mount as shown in FIG. 3C. The housing 302 also includes a pair of
hinges 314 adapted to permit the housing 302 to be opened by
pulling on the handle 306. Of course, the handle can and generally
will be a locking handle which requires a key for entry.
Alternatively, the housing 302 can be equipped with a keyless entry
system that is can be activated by a remote control or via commands
issued from a central control facility to prevent unauthorized
entry into the apparatus 300.
The front surface 308 include an aperture 316 through which light
can pass through a camera lens 318. The apparatus 300 also includes
an antenna 320 mounted on the surface 308 near its top 322 having a
wire 324 leading to communication hardware to be described
below.
Once the apparatus 300 is opened as shown in FIG. 3B, the apparatus
300 includes a camera 326 mounted in the front half 304 of the
housing 302 so that its lens 308 centered in the aperture 316. The
apparatus 300 also includes a digital processing unit (DPU) 328, a
video analog to digital converter 330, and a communication device
332 such as a PIMCIA slot 334 with a mobile access card 336.
The DPU 328 is powered by a DPU power supply 338 mounted in the
back half 310 of the housing 302 via a DPU power cable 340; while
the camera 326 is powered by a camera power supply 342 mounted in
the back half 310 of the housing 302 via a camera power cable 344
The apparatus 300 also includes two fans 346a&b mounted in the
back half 310 of the housing 302.
The DPU 328 is in two-way communication with the camera 326 via a
first electronic connection 348, with the converter 330 via a
second electronic connection 350 and with the communication device
332 via a first electronic connection 352. The communication device
332 is also connected to the antenna 320 via the wire 324, where
the antenna is adapted to permit robust communication between the
apparatus 300 and a remote command and control site located remote
from the site of installation of the apparatus 300 via satellite,
microwave or other broadband or narrow band technology capable of
transmitted data from the apparatus 300 to a remote site.
Alternatively, could have a cable or fiber optics direct connection
between the apparatus 300 and the remote control and command
center.
The apparatus 300 also includes a power strip 354 connected to an
external power conditioner and uninterrupted power supply 356 via a
power in cable 358. The power supply 356 can be an outdoor
uninterrupted power supply (UPS) with 400 w output for up to 18 hr,
12-14 hr actual. The DPU power supply 338 derives its power from
the strip 354 via a first strip cable 360; the camera power supply
342 derives its power from the strip 354 via a second strip cable
362; and the two fans 346a&b derive their power from the strip
354 via third and fourth strip cables 364a&b.
Referring now to FIG. 3C, the apparatus of FIGS. 3A&B is shown
mounted on a pole 366 via a mounting apparatus 368 having two
degrees of rotational freedom, up and down adjustability and in and
out adjustability. The pole 366 includes a lightning rod 370
connected to a ground 372 via a ground wire 374.
One embodiment of the mounting apparatus 368 includes a rotational
ball-pen assembly 376 having a locking screw, set screw or thumb
screw 378 is shown in FIG. 3D. The ball-pen assembly 376 includes a
ball housing 380 affixed to a up and down translation platform 382
and a ball 384 having a neck 386 affixed to a monitoring apparatus
mount 387 affixed to a back surface 312 of the back half 310 of the
housing 302. The ball-pen assembly 376 permits the monitoring
apparatus 300 to be tilted so that its camera aperture 316 is
properly aligned with the stack or other object that the monitoring
system 300 is installed to monitor (stacks, refinery units, heat
exchange units, chemical reactor units, power plant water outlets,
steam generation units, etc.). The translation platform 382 is
adapted to translate via a groove 388 in a pole mounting plate
assembly 390. The translation platform 382 is held in place by to
groove engaging screws 392. The pole mounting plate assembly 390
includes a pole plate 394 affixed to the pole 366 and an adjustable
plate 396, which comprises the groove into which the translation
platform 382 is mounted. The adjustable plate 396 is adapted to be
separated from the pole plate 394 by screws 398, which force the
plates 394 and 396 to separate or come together depending on the
direction the screws are turned. Other mounting apparatuses can be
used as well provided that they at least permit two degrees of
rotational freedom so that the camera aperture of the monitoring
unit can be properly aligned with the object to be imaged. Up and
down and in and out adjustability are optional, but are often found
to be beneficial then installing the unit as the mounting apparatus
does not have to be very precisely attached to the pool. Of course,
the extent of rotation freedom will be limited by the ball-pen
assembly and the size and weight of the monitoring unit, the size
and weight of the mounting apparatus and other factors all within
the design capability of an ordinary artisan in the field of
mounting equipment on poles with differing rotational and/or
translational degrees of freedom. The types of mounts that can be
used are any camera or telescope mount that provides at least two
rotational degrees of freedom, where translation and in and out
adjustment can be made when the unit is being installed or
translational adjustment can simply be an adjustable pole strapping
assembly.
Multi-Detector Imaging Subsystem
Referring now to FIG. 4, an embodiment of an imaging apparatus with
multiple filters of this invention, generally 400, is shown to
include a camera housing 402. The camera housing 402 includes a
camera 404 having an aperture 406 through which light passes into
the camera's interior. The camera housing 402 also includes a four
filter carousel 408 including four filters 410a-d. The carousel 408
is mounted on a drive shaft 412 of a motor 414. The motor 414 is
adapted to change filters so that the camera can be used to view
different properties of the target site such as thermal emission
profiles, effluent components (S.sub.xO.sub.y, N.sub.xO.sub.y,
CO.sub.2, hydrocarbons, water, etc. or mixtures or combinations
thereof, where x is an integer having a value between 1 and 3 and y
is an integer having a value between 1 and 8). The motor 414 is
adapted to be controlled by the DPU 328 so that the system 300 can
collect data on different properties of the site by selectively
switching between filters. The apparatus 400 can be used with any
of the imaging apparatuses of FIGS. 1-3.
Referring now to FIG. 5, an embodiment of a multiple camera imaging
apparatus of this invention, generally 500, is shown to include a
housing 502. The housing 502 includes four filters 504a-d and four
cameras 506a-d having their apertures 508a-d aligned with the
filters 504a-d so that light passes through the filters 504a-d
through the apertures 508a-d and into the cameras 506a-d. The
cameras 506a-d are connected to the DPU or to the converter and
then the DPU, where the DPU is designed to capture, process and
transmit the captured camera data. The apparatus 500 can be used
with any of the imaging apparatuses of FIGS. 1-3.
Referring now to FIG. 6, an embodiment of an imaging apparatus with
a beam splitter of this invention, generally 600, is shown to
include a housing 602. The housing 602 includes surface mounted two
filters 604a-b and two single detector cameras 606a-d having their
apertures 608a-b aligned with the filters 604a-b so that light
passes through the filters 604a-b through the apertures 608a-b and
into the cameras 606a-b. The housing 602 also includes a
multi-detector optical detection apparatus or camera 610 having a
detector aperture 612 situated within a housing aperture 614 in the
housing. Light entering through the detector aperture 612 is split
into two beams 616a-b by a beam splitter 618. The first light beam
616a passes through a first detector filter 620a and into a first
detector 622a, while the second light beam 616b passes through a
second detector filter 620b and into a second detector 622b. The
two single channel cameras 606a-b and the multi-channel camera or
optical detector 610 are connected to the DPU or to the converter
and then the DPU, where the DPU is designed to capture, process and
transmit the captured camera data. The apparatus 600 can be used
with any of the imaging apparatuses of FIGS. 1-3.
Referring now to FIG. 7, another embodiment of an imaging apparatus
with a compound beam splitter of this invention, generally 700, is
shown to include a housing 702. The housing 702 includes a
multi-detector optical detection apparatus or camera 704 having a
detector aperture 706 situated within a housing aperture 708 in the
housing. Light entering through the detector aperture 706 is split
into four beams 710a-d by a compound beam splitter 712. The first
light beam 710a passes through a first detector filter 714a and
into a first detector 716a; the second light beam 710b passes
through a second detector filter 714b and into a second detector
716b; the third light beam 710c passes through a third detector
filter 714c and into a third detector 716c; while the fourth light
beam 710d passes through a fourth detector filter 714d and into a
fourth detector 716d. The multi-channel camera or optical detector
704 is connected to the DPU or to the converter and then the DPU,
where the DPU is designed to capture, process and transmit the
captured camera data. The apparatus 700 can be used with any of the
imaging apparatuses of FIGS. 1-3.
Multi-Site System
Referring now to FIG. 8, an embodiment of a multi-site system of
this invention, generally 800, shown to include a center facility
802 that includes computer hardware and software, communications
hardware and software and sufficient servers to support a plurality
of site monitoring system 804a-z, where the term a plurality means
between 2 and a number limited only by the number of sites amenable
to monitoring by this type of a system. Clearly, the upper limit
can be many thousands if not many hundreds of thousands of sites.
The sites 804a-z are in data communication with the facility 802
via communication pathways 806a-z, which can be wired and/or
wireless, but most often will be wireless. Of course, if the data
is being transmitted via a commercial or private broadband wireless
provider, part of the connection can be wireless and part wired,
where the wired part would represent data being received wireless
into an intranet (private internet) or open internet like the world
wide web.
The data from the monitoring system 804a-z can be raw data,
partially processed data or fully processed data. The facility 802
receives this data as is and performs would ever additional data
processing required to obtain site specific data-capacity
utilization or output activity data, effluent compositional data,
effluent production volume data, etc. This process data is then
stored on a site specific basis in database on the servers in the
facility 802. This accumulated data can then be analyzed on any
combination of monitoring systems basis. Thus, if monitoring is
occurring at all sites of a particular type such as power plants,
then grid integrity reports can be generated to show trends, to
identify problems and to predict future supply, demand and
pricing.
The system 800 also includes a plurality of end users 808a-z, where
the end user plurality can be from 2 to a very large number into
the millions of end users. Each end user 808a-z is are in data
communication with the facility 802 via communication pathways
810a-z, which can be wired and/or wireless, but most often will be
wireless. Of course, if the data is being transmitted via a
commercial or private broadband wireless provider, part of the
connection can be wireless and part wired, where the wired part
would represent data being received wireless into an intranet
(private internet) or open internet like the world wide web.
Methods for Collecting, Analyzing and Distributing Plant Activity
or Utilization Data
Referring now to FIG. 9, an embodiment of a process to obtain a one
hundred percent plant or plant unit output capacity, generally 900,
is shown as a flow chart diagram. The process 900 includes a start
step 902, which becomes active after the imaging apparatus has been
installed at a desired site. After installation, the imaging unit
is set up in a set step 904, which generally involves insuring that
all components of the imaging unit are working, that the imaging
unit is in communication with the remote processing center and
insuring that the imaging unit is functioning properly. Once the
imaging unit is set up, the imaging unit is adjusted in an
adjustment step 906 by rotating and/or translating the unit on its
mount so that the imaging camera or cameras are property aligned
with the site to be monitored. A test image is then acquired in an
acquisition step 908. The acquired image is then scanned to define
active regions within the image in a define active regions step
910. The active regions represent that part of the entire image
that will be monitored in all subsequent image acquisitions and can
include parts of the operational unit such as a stack, piping, heat
exchange units, etc. and/or effluent streams or plumes. Once the
active regions are defined, the regions are processes to produce
data that can be related to plant activity, unit activity, capacity
utilization, effluent production, effluent compositions, etc. in a
process active regions step 912. The results are then tested in a
conditional pass acquisition test (PAT) step 914. If the imaging
unit has been adjusted so that the acquired image maximizes data
collections of the target site(s) within the plant, then control is
transferred along a YES branch 916 to an acquire image step 918;
otherwise control is transferred along a NO branch 920 to the
adjustment step 206. This NO loop is continued until the data
passes the conditional test 814. The acquired image is then
processed to compute a plant or unit output value in a process
active regions step 922. The value is then sent to a compare step
or self-consistent value (SCV) step 924, where the current value is
compared to a previous value or a set of previous values until the
values being compared differ by less than a specified percent
error. If the difference is greater than the error, then control is
transferred along a NO branch 926 to the acquire image step 818 for
reacquisition; otherwise control is transferred along a YES branch
928 to a set 100% value step 930. Of course, it should be
recognized that the 100% is set when the unit or plant is operating
at full capacity. When a unit is initially installed; there is not
guarantee that the plant or unit being monitored is actually
operating at 100% capacity. However, this routine can be used to
set an initial 100% value. If later, the value jumps and remains
that the actual 100% valve, then the 100% can be updated. This same
updating may occur with the plant or unit undergoes modifications,
de-bottlenecking, or any other change that can increase or decrease
100% capacity value.
Referring now to FIG. 10, an embodiment of a process to obtain
output capacity data, generally 1000, is shown as a flow chart
diagram. The process 1000 begins with a start step 1002. After the
routine is started, an image is acquired in an acquire image step
1004. The acquired image is then process to extract data from the
active regions within the image in a process step 1006. The active
region data is then used to compute output activity, utilization
capacity and/or effluent compositional data in a compute step 1008.
The output data is then transmitted to a customer in a transmit
step 1010 and a revenue is collected as a result of the transfer in
a collect step 1012. The process 900 also includes a conditional
step 1014, where the process can be stopped by an interruption in
collected revenue, discontinuing of an account or by supervisor
intervention. If no exit event has occurred, then controlled is
transferred along a NO branch 1016 to the acquire image step 304;
otherwise control is transferred along a YES branch 1018 to a stop
step 1020. Of course, in general, the program will not terminate,
but will continue data collection and transmission until no revenue
stream is obtained. However, the program could also be continued to
accumulate information for periodic compilation and sale.
Alternatively, the transmit step 910 can simply be a posting of the
results to secure website or a secure server and the end user would
simply logon into an account on the website or server and obtain
the posted data.
Referring now to FIG. 11, another embodiment of a process to obtain
output capacity data, generally 1100, is shown as a flow chart
diagram. The process 1100 begins with a start step 1102. After the
routine is started, an image is acquired in an acquire image step
1104. The acquired image is then process to extract data from the
active regions within the image in a process step 1106. The active
region data is then used to compute output activity, utilization
capacity and/or effluent compositional data in a compute step 1108.
The data is then accumulated for a period of time, either set,
variable or interruption triggered in an accumulate step 1110.
Control is then transferred to a report period test (RPT) step
1112. If the period limit or trigger has not occurred, then control
is transferred along a NO branch 1114 to the acquire image step
404; otherwise control is transferred along a YES branch 1116 to a
product output report step 1118. Once the accumulated output report
is produced, the report is transmitted to a customer in a transmit
step 1120 and revenue is collected in a collect step 1122. The
process 400 also includes a conditional step 1124, where the
process can be stopped by an interruption in collected revenue,
discontinuing of an account or by supervisor intervention. If no
exit event has occurred, then controlled is transferred along a NO
branch 1126 to the acquire image step 304; otherwise control is
transferred along a YES branch 1128 to a stop step 1130. Of course,
in general, the program will not terminate, but will continue data
collection and transmission until no revenue stream is obtained.
However, the program could also be continued to accumulate
information for periodic compilation and sale. Alternatively, the
transmit step 1020 can simply be a posting of the results to secure
website or a secure server and the end user would simply logon into
an account on the website or server and obtain the posted data.
Referring now to FIGS. 12A-C, three preferred embodiments of a
process active region subprocess are described, generally 1200,
shown as a flow chart diagram. Looking at FIG. 12A, the subprocess
starts with an extraction step 1202, where pixels associated with
the active regions are extracted from the acquire image. Next, the
"on" pixels are determined within the active regions, i.e., the
pixels containing more than a background pixel intensity or more
than a threshold pixel intensity, is a determination step 1204. The
"on" pixel data are then used to output an active regions density
data in an output step 1206. The resulting "on" pixel data is then
used in the compute output values steps of FIGS. 9, 10 and 11. Of
course, the pixel data derived from this process can relate to
thermal data or compositional data depending on the light being
collected and analyzed.
Looking at FIG. 12B, the subprocess starts with the extraction step
1202, where pixels associated with the active regions are extracted
from the acquire image. Next, the "on" pixels are determined within
the active regions, i.e., the pixels containing more than a
background pixel intensity or more than a threshold pixel
intensity, is a determination step 1204. Once the "on" pixels are
identified, then weather condition correction factors are applied
to the "on" pixel count in apply step 1208. These corrections are
intended to correct the pixel data to compensate for weather
conditions. The corrections factors can be determined by either
data accumulated over time or from studies of acquired images under
different weather conditions at constant plant output. The "on"
pixel data are then used to output an active regions density data
in an output step 1206. The resulting "on" pixel data is then used
in the compute output values steps of FIGS. 9, 10 and 11. Of
course, the pixel data derived from this process can relate to
thermal data or compositional data depending on the light being
collected and analyzed.
Looking at FIG. 12C, the subprocess starts with an adjust step
1210, where the active regions are corrected for weather
conditions, such as a change in wind conditions, change in
temperature, etc. After adjusting the active regions, control
proceeds to the extraction step 1202, where pixels associated with
the active regions are extracted from the acquire image. Next, the
"on" pixels are determined within the active regions, i.e., the
pixels containing more than a background pixel intensity or more
than a threshold pixel intensity, is a determination step 1204.
Once the "on" pixels are identified, then weather condition
correction factors are applied to the "on" pixel count in apply
step 1208. These corrections are intended to correct the pixel data
to compensate for weather conditions. The corrections factors can
be determined by either data accumulated over time or from studies
of acquired images under different weather conditions at constant
plant output. The "on" pixel data are then used to output an active
regions density data in an output step 1206. The resulting "on"
pixel data is then used in the compute output values steps of FIGS.
9, 10 and 11. Of course, the pixel data derived from this process
can relate to thermal data or compositional data depending on the
light being collected and analyzed.
Experimental Data Analysis
Referring now to FIG. 13, a plot of data collected form a three
stack facility showing the thermal data image of the three stack in
the facility from an IR camera located approximately 1 km from the
facility.
Referring now to FIG. 14, depicted is a plot of daily output
activity for the facility in FIG. 13.
All references cited herein are incorporated by reference. While
this invention has been described fully and completely, it should
be understood that, within the scope of the appended claims, the
invention may be practiced otherwise than as specifically
described. Although the invention has been disclosed with reference
to its preferred embodiments, from reading this description those
of skill in the art may appreciate changes and modification that
may be made which do not depart from the scope and spirit of the
invention as described above and claimed hereafter.
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